HR Chapter 04

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual
Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS
November 15, 2012

Rev 1 Page 1
CHAPTER 4.0 TABLE OF CONTENTS

4.0 PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS............................... 3
4.1 SCOPE................................................................................................................................... 3
4.2 GENERAL ............................................................................................................................ 3
4.2.1 Program Requirements................................................................................................. 3
4.2.2 Qualification Prerequisites ........................................................................................... 3
4.2.3 Physical Examination and Substance Abuse Testing Requirements ........................... 4
4.2.4 Substance Abuse Testing for Commercial Motor Vehicle Drivers ............................. 5
4.3 TRAINING AND QUALIFICATION PROGRAMS ........................................................... 5
4.3.1 Previous Training and Qualification ............................................................................ 6
4.3.2 Training Subjects ......................................................................................................... 6
4.3.3 On-the Job Training ..................................................................................................... 6
4.3.4 On-the-Job Evaluations ................................................................................................ 7
4.3.5 Qualification ................................................................................................................ 8
4.3.6 Requalification ............................................................................................................. 8
4.4 RETRAINING....................................................................................................................... 10
4.5 WRITTEN AND PERFORMANCE TESTS ........................................................................ 10
4.6 TRAINING AND QUALIFICATION RECORDS ............................................................... 10
4.6.1 Training Completion Records ...................................................................................... 10
4.6.2 Course Records ............................................................................................................ 11
4.6.3 Qualification Cards ...................................................................................................... 11
APPENDICES
Appendix A Training Subject Content by Activity and/or Equipment .............................................. 12

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4.0 PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

4.1 SCOPE
This section specifies qualification and training requirements for personnel with the following
responsibilities:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Direct hoisting and rigging (H&R) activities

Supervise H&R activities
Perform H&R activities
Inspect and maintain H&R equipment
Provide technical approval of procedures, lift plans or work instructions for H&R activities
Develop lift plans
Provide signals for H&R activities
Train and evaluate personnel for H&R activities and equipment operation
Provide safety oversight
Perform H&R engineering functions
Contracting organizations shall review, verify, and document that subcontractors have an acceptable
training and qualification program. The contracting organization shall ensure that the program meets the
requirements of this section to ensure that personnel are qualified to perform work covered by this
Manual.
NOTE: Refer to 29 CFR 1926, Subpart R, for special H&R requirements relating to steel erection.
4.2 GENERAL
4.2.1 Program Requirements
Personnel shall be trained and qualified to a level of proficiency consistent with their assigned tasks.
Managers responsible for work assignments shall ensure that work assignments do not exceed personnel
qualifications. Posting a list of qualified operators adjacent to or on appropriate equipment is
recommended.
4.2.2 Qualification Prerequisites
Personnel whose work falls within the scope of this Manual shall meet the following qualifications.
1. Be at least 18 years old
2. Be able to communicate in written and spoken English
3. Be able to meet the physical requirements of the job assignment

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4.2.3 Physical Examination and Substance Abuse Testing Requirements

4.2.3.1 Physical Examination Requirements for Mobile Locomotive, and Cab- or Pulpit-Operated
Overhead Crane Operators
Before operating mobile, locomotive, and cab- or pulpit-operated overhead cranes, operators, operator
trainees, maintenance personnel, and inspectors shall pass a crane operator physical examination initially
and at least every 36 months thereafter. The physical examination shall meet the requirements of the
American Society of Mechanical Engineers (ASME) B30.2, B30.17, and B30.5. The operator shall retain
evidence of successfully passing the physical examination.
A mobile crane operator who successfully passes a commercial motor vehicle (CMV) drivers physical in
accordance with the requirements of 49 CFR 391 Subpart E, Physical Qualification and Examination,
satisfies the crane operator physical exam requirements.
NOTE: A companys contract, agreement, and/or memorandum of understanding regarding physical
examinations will determine the medical examiner chosen to perform the physical examination. In
general, the Site Occupational Medical Director will clear all medical examinations.
4.2.3.2 Substance Abuse Testing for Mobile Crane Operators
Mobile or locomotive crane operators, operator trainees, maintenance personnel, and inspectors shall
pass, with a negative result, a substance abuse test initially and at least every 36 months thereafter. A
recognized laboratory shall perform the test.
4.2.3.3 Crane Operator Certification
Operators of the following cranes shall be certified by an operator testing organization that is accredited
by ANSI and a nationally recognized accrediting agency as defined in OSHA 1926.1427 (Option 1). The
certification shall meet the previous training requirements defined in 4.3.1, Previous Training and
Qualification. NOTE: Maintenance and inspection personnel that are required to operate cranes in the
performance of their duties are excluded from this certification requirement; however, they must maintain
mobile crane operator qualification under the Hanford Site training requirements and this chapter.
Articulating cranes (such as knuckle-boom cranes)

Crawler cranes
Floating cranes
Cranes on barges
Locomotive cranes
Mobile cranes (wheel-mounted, rough-terrain, all-terrain, commercial truck-mounted, and boom
truck cranes)
Multi-purpose machines when configured to hoist and lower (by means of a winch or hook) and
horizontally move a load
Industrial cranes (such as carry-deck cranes)
Dedicated pile drivers

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Service/mechanic trucks with a hoisting device when used for operations other than maintenance
or repairs
A crane on a monorail when temporarily installed
Tower cranes (such as a fixed jib, i.e., hammerhead boom, luffing boom, self-erecting)
Pedestal cranes
Portal cranes
Overhead and gantry cranes when temporarily installed
Straddle cranes
Side boom cranes
Derricks
Digger derricks when used for operations other than placing or removing poles and handling
associated materials to be installed on or removed from the poles.
Any variations of such equipment
4.2.4 Substance Abuse Testing for Commercial Motor Vehicle Drivers

The CMV definition found in 49 CFR 383.5 (see Appendix A, commercial motor vehicle, for the
definition), shall apply to truck-mounted mobile cranes and forklifts designed for highway use with a
gross vehicle weight rating of 26,001 lb or more.
CMV drivers are subject to substance abuse testing independent of the mobile crane operators substance
abuse testing requirements (see Section 4.2.3.2). The same substance abuse test can meet both CMV and
crane operator requirements, but the crane operator must be retested at least every 36 months.
4.3 TRAINING AND QUALIFICATION PROGRAMS

Contractors shall have a documented training and qualification program that includes the following
elements.
1. Classroom or computer-based training
2. Written tests
3. On-the-job training (OJT) (see Section 4.3.3)
4. On-the-job evaluations (OJE) (see Section 4.3.4)
5. Established and documented pass/fail criteria (see Section 4.5)
The Hanford Hoisting and Rigging Training Program Description is located at:
http://www.hanford.gov/files.cfm/HR_TPD.pdf

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4.3.1 Previous Training and Qualification

Documented evidence of previous training or experience may be accepted to meet training requirements.
1. Previous training or experience may include the following:
a. Vendor or equipment manufacturer training
b. Completion of an apprenticeship program
c. Journeyman status in an applicable trade
2. For previous training to be acceptable for Hanford Site qualification, documented evidence of the
topics listed in Appendix A of this chapter shall be included, along with the type and class of
equipment operated. For qualifications not related to equipment operation, personnel shall have
documented evidence of training related to an activity covered by this Manual. Previous training
must include a written knowledge test. As a minimum, documented evidence may be any of the
following.
a. Certificates of training (See Note 4.1)
b. Journeyman card or documents issued by a trade union
c. A degree or accreditation from a college or trade school
3. When previous training or experience are reviewed for compliance to this manual, accepted and
documented, personnel shall be considered qualified after they have satisfactorily completed an
On-the-Job Evaluation (OJE) for the equipment or activity being performed. Operators of mobile
locomotive and cab- or pulpit-operated overhead cranes shall have met the Physical Examination
and Substance Abuse Testing requirements identified in 4.2.3.
4. When previous training or experience is reviewed for compliance to this manual and not
accepted, personnel will be required to complete the applicable Hanford Site approved course, the
applicable challenge examination for the approved course, or an off-site course that meets the
requirements of this manual.
4.3.2 Training Subjects
Appendix A, Training Subject Content by Activity and/or Equipment, contains subjects (listed by
qualification area) that should be included in the training process. All approved courses must include a
written knowledge test.
4.3.3 On-the Job Training
Contractors shall make OJT available for crane and forklift operators. If a forklift or crane operator will
use attachments, the OJT shall include installation and use of approved attachments (Example: Forklift
boom and barrel-handling attachments and crane jibs and boom extensions). Personnel shall satisfy
training requirements (see Appendix A, Training Subject Content by Activity and/or Equipment) before
performing OJT. The OJT shall be based on the equipment manufacturers operating instructions, typical
tasks, operating environment, and facility or contractor-specific procedures.
The OJT shall provide training and practice under the direct supervision of a qualified operator or
qualified OJT instructor in the appropriate work environment, using the appropriate OJE forms of Section
4.3.4. Complexity of equipment and tasks, along with the operators experience shall determine the need
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for OJT. Management may allow previously qualified or experienced personnel to bypass the OJT and
undergo an OJE (see Section 4.3.4). The completion or bypassing of OJT shall be documented.
4.3.4 On-the-Job Evaluations
Sections 4.3.4.1 through 4.3.4.4 contain classes of cranes, forklifts, or H&R activities that require
personnel to pass an OJE before being granted qualifications. The OJEs shall have pass and fail criteria,
and shall require personnel to demonstrate that they have the knowledge and skills to safely operate
equipment or perform the H&R function. Personnel shall be evaluated for each type and class of
equipment they operate. Personnel who pass an evaluation for a type and class of equipment are
considered qualified on all equipment of the same type and class. Contractors, facilities, and
organizations may choose to implement additional facility-specific OJT and/or OJE requirements.
OJEs are required to be documented. As a minimum, documentation shall contain:
1.
2.
3.
4.
5.
6.
7.
The name and signature of the person being evaluated

Name and signature of the qualified evaluator
Evaluation score
Instructions for the evaluator and the person being evaluated
Type and class of equipment or activity
Attachments
Date of the evaluation
Examples of OJE forms can be found on the Hanford Intranet at http://apweb01.rl.gov/siteforms/.

4.3.4.1 Powered Industrial Trucks
Personnel are qualified to operate powered industrial trucks according to the following designations. See
Chapter 6.0, Forklift Trucks, for sample views of each industrial truck class designation.
Class
1&2
3
4&5
6
7
8
Powered Industrial Truck Type

Electric motor, sit-down and stand-up rider, counter balanced, and narrow-isle trucks,
solid and pneumatic tires
Electric motor, hand trucks or hand/rider trucks, solid tires
Internal combustion engine trucks, solid and pneumatic tires
Electric and internal combustion engine tractors, solid and pneumatic tires
Rough terrain vertical-mast forklift trucks.
Rough terrain telescopic boom forklift trucks
4.3.4.2 Overhead Cranes

Personnel are qualified to operate overhead cranes according to the following designations:
Class
1
2
Overhead Crane Type

Overhead cranes, floor-operated (Facilities may designate specific qualifications to
selected cranes.)
Overhead cranes, cab-operated.
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4.3.4.3 Mobile Cranes

Personnel are qualified to operate mobile cranes according to the following designations:
Class
1
2
3
4
5
6
7
8
9
10
Mobile Crane Type

Lattice boom truck cranes (multiple control stations)
Lattice boom crawler cranes
Telescopic boom cranes, (single control stations)
Telescopic boom cranes, ((multiple control stations)
Commercial truck-mounted crane telescoping boom
Commercial truck-mounted crane non-telescoping boom
Telescoping boom crawler crane
Lattice boom wheel mounted (single control station)
Telescoping boom fixed control station (non-rotating operator cab)
Locomotive cranes
4.3.4.4 Training and Evaluation

Personnel are qualified to perform H&R OJT instruction or evaluation once they are designated as an Onthe-Job Training Instructor or an On-the-Job Evaluator.
4.3.5 Qualification
Personnel shall be considered qualified when they accomplish the following:
1. Satisfactorily complete Hanford Site approved training, testing, and qualification or meet the
requirements of previous training (see Section 4.3.1)
2. Satisfactorily complete equipment specific On-the-Job Training (OJT) for equipment operators.
Management may determine that previous qualification or experience fulfills the requirement for
OJT.
3. Pass an equipment specific OJE for personnel performing rigging activities and equipment
operators.
4.3.6 Requalification
4.3.6.1 Requalification Frequencies
Personnel who perform any of the following tasks shall requalify in those task areas every 60 months:
1. Use rigging or perform rigging activities
2. Function as a designated lead (DL)/lift director
3. Perform OJEs

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4. Operate mobile cranes, overhead cranes, and monorails

5. Develop lift plans
6. Perform signal person duties for H&R activities
7. Perform periodic document inspections of equipment
8. Provide technical approval of lift procedures
9. Provide safety oversight of H&R operations
10. Supervise or direct H&R operations (includes DLs/lift directors)
11. Perform activities as an equipment custodian
12. Maintenance, inspection, or repair personnel who operate mobile cranes, cab- or pulpit-operated
overhead cranes
Personnel who operate forklifts shall requalify every 36 months.
NOTE: It is recommended that personnel who have not performed work or operated equipment, for
which they were trained and qualified, for 12 continuous months be re-evaluated.
4.3.6.2 Requalification Methods
Personnel performing the following activities may be requalified by the methods indicated. Personnel,
who do not satisfactorily complete requalification by an identified method, shall complete training as
listed in Sections 4.3.1.3.
Activity
Requalification Method
Powered industrial trucks (forklifts) operation.
OJE
Overhead crane and monorail operation.
OJE
Mobile crane operation (includes maintenance repair or inspection
OJE
personnel who operate mobile cranes) and advanced rigging activities.
Incidental rigging (using slings, rigging hardware, hoists, and below-theOJE
hook lifting devices).
Inspect mobile or overhead cranes (mechanical or electrical), forklifts,
OJE or written test
wire rope, rigging hardware, below-the-hook lifting devices, hooks, and
hoists.
Approving technical lift procedures, acting as Designated Leader for,
OJE or written test
Safety Oversight or supervision of hoisting and rigging operations.
Acting as equipment custodian.
Written test
On-the-job training or evaluation of personnel. Note: - On-the-job
Written test or OJE.
Trainers and Evaluators must maintain and demonstrate both their
instructional proficiency and technical proficiency.
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4.4 RETRAINING
Retraining shall consist of satisfactorily completing training requirements for that activity or equipment
(see note in paragraph 4.3.6). Personnel shall be retrained when any of the following occurs:
1. Equipment with new operating characteristics is acquired
2. Existing equipment is modified, changing the operation characteristics
3. Personnel receive an unsatisfactory performance evaluation
4. Changes in standards or requirements occur that could affect safety
5. Personnel are directly involved in a documented incident that compromises safety of personnel,
equipment, or the environment in the performance of H&R activities
6. Personnel performance is determined to be unsatisfactory or diminished skill level is observed
4.5 WRITTEN AND PERFORMANCE TESTS

Written, oral, and performance tests shall have established pass/fail criteria, be developed using the
guidance in DOE-HDBK-1205-97, Guide to Good Practices for Design Development and
Implementation of Examinations, and DOE-HDBK-1206-98, Guide to Good Practices for on-the-Job
Training, and require students to demonstrate knowledge and skills identified by training objectives.
4.6 TRAINING AND QUALIFICATION RECORDS

4.6.1 Training Completion Records
Training completion records (TCR) shall:
1. Be maintained by the issuing organization or employer for the duration of qualification
2. Contain written examinations and performance evaluation of knowledge and skills
3. Contain documentation supporting evaluation of previous training and qualifications, when
applicable
4. Indicate the activity and/or equipment type and class for which qualification was issued
5. Contain the name of the qualified individual and the date the qualification was issued
6. Contain the name and signatures of instructors and students, and the date instruction was given
7. Contain the name and signature of the evaluator, the person evaluated, and the date the evaluation
was conducted

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4.6.2 Course Records

The following documents are considered course records:
1. Course description
2. Current lesson plans
3. Student handouts, if applicable
4. Performance evaluations
5. Written examinations or the bank of test questions
4.6.3 Qualification Cards
Qualified personnel may be issued cards identifying their equipment/activity qualifications. Information
on these cards shall be derived from and supported by training and qualification records (see Section
4.6.1). If used, these cards shall contain the following information:
1. Activity covered by the qualification
2. Type of equipment or activity
3. Class of equipment
4. Date of training and/or evaluation
5. Name of qualified individual
6. Signature of qualified individual
7. Name and signature of the OJT instructor
8. Name and signature of the OJT evaluator
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Appendix A Training Subject Content by Activity and/or Equipment

A.
Powered Industrial Truck (Forklift) Operation
Training for operation of powered industrial trucks (forklifts) is divided into three categories and should
cover the following:
1. Fundamentals
a. Inspection and maintenance
b. Responsibilities
c. Standards
d. Operating instructions, warnings, precautions, etc.
e. Braking methods and characteristics
f. Visibility with and without a load
g. Stability characteristics to include center of gravity, stability triangle (with and without a
load or attachments), requirement and approvals for using attachments
h. Controls: location, function, methods of operation, identification of symbols
i. Load-handling capabilities of forks and attachments
j. Fueling and battery charging
k. Guards and protective devices
l. Difference between industrial trucks and automobiles
m. Engine or motor operation
n. Steering and maneuvering
o. Other characteristics
2. Operating Environment
a. Floor or ground conditions, including temporary conditions
b. Ramps and inclines, with and without a load
c. Trailers, railcars, and dock boards, including the use of wheel chocks, jacks, or other
securing devices
d. Fueling and battery-charging facilities
e. Use of classified trucks in areas classified as hazardous because of a risk of fire or
explosion, as defined in ANSI/NFPA 505
f. Narrow aisles, doorways, overhead wires, piping, and other areas of limited clearance
g. Areas where the truck may be operated near other powered industrial trucks or vehicles
h. Operation near pedestrians
i. Use and capacities of elevators
j. Operation near the edge of a dock or improved surface
k. LP gas bottle change-out
l. Other special operating conditions and hazards that could be encountered.

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3. Operation
a. Proper pre-shift inspection and the approved method for removing a truck in need of
repair from service
b. Fork/tine adjustments
c. Load-handling techniques (lifting, lowering, picking up, placing, and tilting)
d. Traveling with a load, without a load, and turning corners
e. Parking and shutdown procedures
f. Other special operating conditions for the specific application
g. Operating safety rules and practices (e.g. Designated Leader [DL]/lift director
assignment)
h. Other rules, regulations, or practices required by the employer at the location where the
powered truck will be used
i. LP gas bottle change-out
j. Lessons learned
k. Hand Signals
l. Operating near power lines
B.
Forklift Inspection and Maintenance
Training for forklift inspection and maintenance should cover the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Inspection criteria
Determining who can make repairs
Fork inspection criteria
Forklift testing criteria
Hydraulic systems
Capacity, operational, maintenance, and name plate requirements
Rated capacity
Stability criteria
Maintenance and rebuilding practices
Forklift type
Controls
Operating mechanism
Components and attachments
Safety and warning devices
Operating instructions
Modifications requirements
Replacement parts and suspect counterfeit items.
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C.
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Wire Rope and Rigging Hardware Inspection and Maintenance
Training for wire rope and rigging hardware inspection and maintenance is divided into four categories
and should cover the following:
1.
2.
3.
Wire Ropes
a. Manufacturer recommendations
b. Standards
c. Lift service return inspections
d. Wire rope replacement criteria
e. Work site receipt
f. Rope storage
g. Unreeling, cutting, seizing
h. Lubrication type and frequency
i.
Replacement
j.
Extra-long rope
k. Frequent, monthly, and periodic
inspection criteria
Slings
a. Documentation
b. Standards
c. Defective slings
d. Rated loads
e. Sling identification
f. Effects of environment
g. Attachments
h. Operating practices
i.
Proof test
j.
Repairs
k. Minimum lengths
l.
Rope grades
m. Rope properties
n. General guidelines and inspection
criteria
l.
m.
n.
o.
p.
q.
r.
s.
t.
u.
Terminal end
Installation
Before initial load cycle
Initial load cycle
New rope stretch
Fastener verification
Replacement documentation
Rope qualification
Lessons learned
Suspect counterfeit items.
o.
p.
q.
r.
s.
t.
u.
v.
w.
x.
y.
z.
aa.
End attachments
Replacement
Cautions and prohibitions
Fabrication
Coatings
Design factors
Removal criteria
Construction
Webbing
Fittings
Marking
Suspect counterfeit items
Lessons learned
Hooks
a. New hooks
b. Standards
c. Throat latches
d. Frequent inspection criteria and intervals
h.
i.
j.
k.
e.
f.
g.
l.
m.
n.
Rigging Hardware
Marking and tagging
Inspection criteria
Periodic inspection criteria and
intervals
Qualification standards
Lessons learned
Proof load testing and tagging

Inspection records
Nondestructive testing
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4.
D.
Below-the-Hook Lifting Devices

a. Design factors
b. Standards
c. Welding
d. Guarding
e. Electrical
f. Analysis
g. Marking
h. Modifications
i.
Initial inspection
l.
m.
n.
o.
p.
q.
r.
s.
t.
j.
Frequent inspection criteria and intervals
u.
k.
Service classifications
v.
Rev 1 Page 15

Inspection records
Repairs
Preventive maintenance
Replacement parts
Testing
Operational tests
Rated load test
Manufacturers certification in lieu
of rated load test
Periodic inspection criteria and
intervals
Lessons learned
Overhead Crane Operation
Training for overhead crane operation should cover the following:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Load and capacity

Math skills
Crane-specific information
Standards
Operational characteristics
Crane performance
Prestart and post-start inspections
Maneuvering and maneuvering skills
Shutdown and securing procedures
Crane manufacturer operation and
maintenance instructions
11.
12.
13.
14.
15.
16.
17.
18.
19
20.

Operator conduct and responsibilities
Operating practices
Attaching the load
Holding the load
Moving the load
Personnel lifting
Signaling and signals
Lessons learned
DL/lift director assignment

E.
Overhead Crane Inspection and Maintenance
Training for overhead crane inspection and maintenance should cover the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Inspection classification
Standards
Frequent inspection criteria and intervals
Periodic inspection criteria and intervals
Determination of conditional hazards
Operating mechanisms (including remote operating systems, if applicable)
Upper-limit devices
Tanks, valves, pumps, lines, and other parts of air or hydraulic systems
Hooks and hook latches
Hoist ropes and end connections
Spooling of rope on drums and sheaves
Deformed, cracked, or corroded members
Bolts, nuts, pins, or rivets
Sheaves and drums
Pins, bearings, wheels, shafts, gears, rollers, locking and clamping devices
Bumpers and stops
Brake system parts
Drive sprockets and excessive drive chain stretch
Controllers, master switches, contacts, limit switches, and push-button stations
Wind indicators
Gasoline, diesel, electric, or other power plants
Motion limit devices
Rope reeving
Function, instruction, caution, and warning labels or plates
Cranes not in regular service
Inspection records
Operational tests for new, reinstalled, altered, repaired, or modified cranes
Rated load test
Maintenance procedure(s)
Adjustments, repairs, and replacements
Lubrication
Rope inspection (see Section C)
Lessons learned
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F.
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Overhead Mechanical and Electrical Hoist Maintenance
Training for overhead mechanical and electrical hoist maintenance should cover the following:
1.
2.
3.
4.
5.
Standards
Hoists not in regular service
Periodic inspection criteria and intervals
Roller chain inspection, maintenance,
and replacement
6. Frequent inspection criteria and
intervals
7. Operational tests
8. Load test
G.
9.
10.
11.
12.
13.
Maintenance procedure
Adjustments, repairs, and replacements
Lubrication
Rope inspection and maintenance (see
Section C)
14. Welded-link chain inspection,
maintenance, and replacement
15. Suspect counterfeit items
16. Lessons learned
Riggers/Signal Persons
Training for rigging activities should cover the following:

1.
2.
3.
4.
5.
6.
Capacities
Math skills
Design factors
Sling angles and effects on capacity
Load weight calculations
Definitions
17.
18.
19.
20.
21.
22.
7.
Load center of gravity, effects and

determination
23.
8.
Inspections
24.
9. Slings, types and applications

10. Rigging hardware, types and applications
25.
26.
11. Below-the-hook lifting devices types,

applications, marking, and inspection
27.
12.
13.
14.
15.
16.
28.
29.
30.
31.
Safety requirements
Safe H&R practices
Attaching the load
Moving the load
Rigger responsibilities
Emergency response
Critical lift requirements
Standards
Lessons learned
Calculating sling loading using load angle
factors, D/d ratios, and multi-leg slings
Calculating the center of gravity and
determining pick points for symmetrically
and unsymmetrically shaped loads
Performing flagging, setup, and working
with mobile cranes
Working from suspended platforms
Working near energized sources and
power lines
Assembling and disassembling lattice
boom cranes and box-boom extensions
and jibs
Performing critical lifts and two-crane lifts
Performing H&R in hostile environments.
Crush/pinch points/struck-by hazards
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H.
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Mobile Crane Operation
Training for mobile crane operation should cover the following:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Mobile crane operation and setup

Load and capacity chart calculations in
various configurations
Load moment indicators (LMI)
Math skills
Crane-specific and cab information
Standards
Operational characteristics
Controls and emergency control skills for
fire and power-line contact
Crane performance and stability
Prestart and post-start inspections
Maneuvering and maneuvering skills
Shutdown and securing procedures
Crane manufacturer operation and
maintenance instructions
Operator conduct and responsibility
15. Operating practices

16. Attaching the load
17.
18.
19.
20.
21.
22.
Holding the load

Moving the load
Personnel lifting
Operating near power lines
Traveling with and without a load
23.
24.
25.
26.
27.

Footing
Refueling procedure
Lessons learned
28. Operator aids.

29. Crush/pinch points/struck-by hazard
NOTE: For other crane types see Chapter 1.0, Introduction.

I.
November 15, 2012

Rev 1 Page 19
Mobile Crane Inspection and Maintenance
Training for mobile crane inspection and maintenance shall include requirements and applicable subjects
of Section H, Mobile Crane Operation, if inspection and maintenance personnel operate mobile cranes
in performance of their duties. Training for mobile crane inspection and maintenance should cover the
following subjects:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23. Travel steering, braking, and locking

devices
Standards
24. Hydraulic and pneumatic hose fittings and
tubing inspection
Control mechanisms adjustments
25. Excessive abrasion or scrubbing of the
outer surfaces
Control mechanisms for excessive wear of 26. Hydraulic and pneumatic pumps, valves,
components
and motors
Control mechanisms contamination by
27. Hydraulic filters
lubricants or other foreign matter
Safety mechanisms for malfunction
28. Cranes not in regular use
Hydraulic hoses
29. Inspection records
Hooks and latches
30. Operator aids
Rope reeving
31. Operational tests
Electrical apparatus
Hydraulic system
Tires
Crane structure and boom
Bolts or rivets
Sheaves and drums
Pins, bearings, shafts, gears, rollers, and
locking devices
Brake and clutch system, parts, linings,
pawls, and ratchets
Load, boom angle, and other indicators
Gasoline, diesel, electric, or other power
plants
Chain drive sprockets and chain
Crane hooks
32.
33.
34.
35.
36.
37.
38.
39.
Crush/pinch points/struck-by hazards

Rated load test
Maintenance procedure
Adjustments and repairs
Functional operating mechanisms
Safety devices
Control systems
40. Braking systems

41. Lubrication
42. Rope inspection (see Section C)
43. Lessons learned

J.
November 15, 2012

Rev 1 Page 20
Equipment Custodian
Training for equipment custodians should cover the following:
K.
1.
2.
3.
Verification of current maintenance

Standards
Verification of current inspection
5.
6.
7.
4.
Verification of current testing
8.
Record keeping
Proper tagging and removal from service
Elements of this manual for the assigned
equipment
Manufacturers operating and
maintenance instructions.
Designated Leader (DL)/Lift Director
Training for DLs/lift directors should cover the following:

1.
2.
3.
4.
5.
6.
L.
Preparation of critical lift procedures

Standards
Proper approval of critical lift procedures
Documented pre-lift meeting
Flagger assignment and identification
Personnel qualification
7.
8.
9.
10.
11.
Equipment selection
Equipment setup and positioning
Work area overview
Directing operations
Elements of this Manual for the work and
equipment used
5.
Proper tagging of unsafe or restricted-use

equipment
Custodian notifications
DL/lift director assignments
Elements of this Manual for work
assignments of the assigned crew
Supervisor
Training for supervisors should cover the following:

1.
2.
3.
4.
M.
Qualified personnel for equipment

operation
Standards
Safe operation of equipment
Preplanned and approved H&R
instructions
6.
7.
8.
Lift Procedure Technical Approver/Lift Plan Developer
Training for technical approvers/lift plan developers should cover the following:
1.
2.
Chapter 3, Critical and Special Lifts, of this Manual

Elements of this Manual for the work to be done and equipment to be used. For subjects
refer to each category of equipment and activity listed in Appendix A, Training Subject
Content by Activity and/or Equipment, of this Chapter.

N.
November 15, 2012

Rev 1 Page 21
On-the-Job Training Instructor
OJT instructors shall have the technical information in the subject area of training assignments and should
be trained in the following:
1.
2.
3.
O.
OJT techniques
Demonstrations
Hands-on exercises
4.
5.
6.
Performance evaluation
Use of OJT forms
Records management
On-the-Job Evaluator
On-the-job evaluators shall have the technical information on the subject area of evaluations, be qualified
to perform OJEs of proper operator actions, and should be trained in the following:
1.
2.
3.
P.
Evaluation techniques
Test administration
Performance evaluation
4.
5.
Use of OJE forms

Records management
Classroom Instructors
Classroom instructors presenting training on subjects identified in Appendix A, Training Subject Content
by Activity and/or Equipment, of this chapter shall be technically competent and trained in the following
instructional areas
Q.
1.
2.
3.
Standards
Instructional techniques
Test administration
4.
5.
Instructional materials and media

Learning Objectives
6.
7.
8.
Lesson plans
Lessons learned in subject area
Concepts of systematic approach to
training
9. Principles of learning
10. Records Management
Safety Oversight
Training for personnel responsible for safety oversight of hoisting and rigging activities should cover the
following:
1.
2.
General safety standards related to H&R activities.

The DOE/RL-92-36 Hanford Site Hoisting and Rigging Manual content overview and
pertinent safety requirements for personnel and equipment.

R.
November 15, 2012

Rev 1 Page 22
Rigging Engineer
Candidates for rigging engineers should have a minimum of two years experience in H&R related work.
(NOTE: Designation as a rigging engineer does not qualify personnel to perform design calculations. A
Registered Professional Engineer (RPE) typically performs design calculations of hoisting and rigging
equipment.)
Training for Rigging Engineers shall cover the following:
1. The contents of this Manual
2. The OSHA and ASME standards referenced in Chapter 21, References and Bibliography, of this
Manual
3. Reviewing structural calculations of lift points or lifting devices to determine compliance to
applicable standards
4. Personnel assignments and responsibilities
5. Critical and special lift criteria
6. Slings, rigging hardware, and below-the-hook lifting devices characteristics and design factors
7. Slings, rigging hardware, and below-the-hook lifting devices removal from service criteria
8. Mobile cranes, hoists , overhead cranes, and forklift operational characteristics, setup, and
operation
9. Mobile cranes, hoists, overhead cranes, and forklift testing and inspection requirements and
removal from service criteria
10. Mobile cranes, hoists, overhead cranes, and forklift attachments and effects on capacities
11. Mobile crane load chart calculations and capacities for specific configurations
12. Rope re-reeving
13. Suspended platform use and requirements
14. Working around electrical energized sources requirements
15. Crane, forklift, and rigging rated/proof load testing requirements
16. Calculating slings and rigging hardware loading and effects on capacity
17. Load weight calculations
18. Determining pick points
19. Calculating load center of gravity
20. Safe H&R practices

S.
February 18, 2014

Rev 1 Page 23
Assembly / Disassembly Director
Training for personnel responsible for Assembly/Disassembly of cranes activities shall cover the
following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Assembly/Disassembly procedures
Reviewing procedures
Blocking material
Crew instructions
Proper location of blocking
Verifying assist crane loads
Tasks, assignments, and associated hazards
Boom and jib pick points
Hazardous positions/locations during assembly and disassembly
Center of gravity
Protecting assembly/disassembly crew members out of operator view
Snagging
Working under the boom, jib, or other components
Stability upon pin removal
Capacity limits
Struck by counterweights
Addressing specific hazards
Boom hoist brake failure
Site and ground bearing conditions
Loss of backward stability
Wind speed and weather
Weight of components
Components and configuration
Manufacturer instructions
Post-assembly inspection
Shipping pins
Outriggers and Stabilizers
Rigging
Dismantling (including dismantling for changing the length of booms and jibs)
Assembly/Disassemblyemployer procedures
Power line safety during assembly/disassembly operations
Wire Rope
Fall Protection
November 15, 2012
T.
Rev 1 Page 24
Mobile Crane Operator and Personnel Assigned to Work Around and with Mobile Cranes
Mobile Crane Operators and personnel assigned to work around and with mobile cranes shall receive
training for working around power lines that, as a minimum, includes the following:
1. The procedure to be followed in the event of electrical contact with a power line. Such training
must include:
a. Information regarding the danger of electrocution from the operator simultaneously
touching the equipment and the ground.
b. The importance to the operators safety of remaining inside the cab except where there is
an imminent danger of fire, explosion, or other emergency that necessitates leaving the
cab.
c. The safest means of evacuating from equipment that may be energized.
d. The danger of the potentially energized zone around the equipment (step potential).
e. The need for crew in the area to avoid approaching or touching the equipment and the
load.
2. Safe clearance distance from power lines.
3. Power lines are presumed to be energized unless the utility owner/operator confirms that the
power line has been, and continues to be, de-energized and visibly grounded at the worksite.
4. Power lines are presumed to be un-insulated unless the utility owner/operator or a registered
engineer who is a qualified person with respect to electrical power transmission and distribution
confirms that a line is insulated.
5. The limitations of an insulating link/device, proximity alarm, and range control (and similar)
device, if used.
6. The procedures to be followed to properly ground equipment and the limitations of grounding.
U.
Below-the-Hook Lifting Device Operation
Training on operation of Below-the-Hook Lifting (BTH) Devices should cover the following as
applicable.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Manufacturers suggested operating procedures.

Instructions in any special operations or precautions.
Condition and configuration of the load required for operation of the lifter.
The load rating of the lifting device and the capacity of the hoisting equipment.
Application of the lifter to the load and adjustments.
Proper attachment of adapters on a lifting device for special load handling.
Proper storage of the lifter.
Demonstration of the ability to operate the BTH Lifting Device as instructed.
Charging of the battery (if required).
Purpose of indicators, meters, or alarms on a vacuum lifter.

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DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

November 15, 2012

CHAPTER 4.0 TABLE OF CONTENTS

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

This page intentionally blank

November 15, 2012

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

4.0 PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

Direct hoisting and rigging (H&R) activities

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

4.2.3 Physical Examination and Substance Abuse Testing Requirements

Articulating cranes (such as knuckle-boom cranes)

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

4.2.4 Substance Abuse Testing for Commercial Motor Vehicle Drivers

4.3 TRAINING AND QUALIFICATION PROGRAMS

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

4.3.1 Previous Training and Qualification

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

The name and signature of the person being evaluated

Examples of OJE forms can be found on the Hanford Intranet at http://apweb01.rl.gov/siteforms/.

Powered Industrial Truck Type

4.3.4.2 Overhead Cranes

Overhead Crane Type

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

4.3.4.3 Mobile Cranes

Mobile Crane Type

4.3.4.4 Training and Evaluation

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 18, 2014

4. Operate mobile cranes, overhead cranes, and monorails

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

4.5 WRITTEN AND PERFORMANCE TESTS

4.6 TRAINING AND QUALIFICATION RECORDS

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

4.6.2 Course Records

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

Appendix A Training Subject Content by Activity and/or Equipment

Powered Industrial Truck (Forklift) Operation

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Forklift Inspection and Maintenance

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS

Wire Rope and Rigging Hardware Inspection and Maintenance

Proof load testing and tagging

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual

November 15, 2012

Chapter 4.0 - PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS